Microneedle Array Grid Support for Skin Adaptability

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Solution Overview

Problem

Existing microneedle array manufacturing methods face challenges due to hydrophobic properties between casting molds and liquid formulations, leading to issues with uniform power transmission and adaptability to uneven skin surfaces.

Innovation Solution

A microneedle array with a grid structure support layer that connects microneedles for stiffness and flexibility, allowing for uniform penetration and easy application to curved or uneven areas, combined with a molding process that forms channels for embedding or overmolding a grid structure with materials like PVP or textile fibers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a support layer is added to connect microneedles for stability, then stiffness and power transmission are improved, but the layer thickness must be minimized to reduce mass while maintaining flexibility for uneven skin surfaces

Engineering Contradiction:

Improvestiffness of support layerVSAvoidadaptability to uneven skin surfaces

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The support layer is segmented into a grid structure with discrete bars arranged in rows and columns, creating a framework that provides structural support while maintaining flexibility. This segmentation allows the support layer to adapt to uneven skin surfaces while preserving stiffness for power transmission.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support layer is designed as a thin grid structure that can flex and conform to uneven skin surfaces. The grid bars are arranged to provide structural integrity while allowing the overall layer to remain flexible, enabling application to curved or uneven areas of the skin.

Inventive Principle:

Principle #30Flexible shells and thin films

2Adaptability or versatility

If the support layer thickness is reduced to minimize mass, then flexibility and adaptability improve, but power transmission capability deteriorates

Engineering Contradiction:

Improveflexibility of microneedle arrayVSAvoidpower transmission capability

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The support layer is divided into discrete grid bars arranged in a pattern, creating a lightweight structure that maintains flexibility while providing sufficient structural support for power transmission. The segmented design allows for optimized material distribution.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support layer combines grid structure elements with the microneedle array to create a composite system that achieves both flexibility and power transmission capability. The grid structure acts as a reinforcing framework that enhances mechanical properties without adding significant mass.

Inventive Principle:

Principle #40Composite materials

3Adaptability or versatility

If a grid structure is introduced to improve support and flexibility, then manufacturing complexity increases due to additional channels and embedding processes

Engineering Contradiction:

Improveflexibility of microneedle arrayVSAvoidcomplexity of molding process

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The grid structure is formed in the molding process by providing channels in the molding that receive and shape the support layer material. This preliminary preparation of the molding structure simplifies the overall manufacturing process by integrating the grid formation step into the existing molding operation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The molding acts as an intermediary tool that transforms the support layer material into the desired grid structure. By using the molding's channels and cavities, the complex grid pattern is formed automatically during the manufacturing process, reducing the need for additional processing steps.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS20230098653A1Microneedle Array, Molding for Manufacturing a Microneedle Array, and Method for Manufacturing a Microneedle Array

Publication Date: 2023.03.30 LTS LOHMANN THERAPIE SYST AG

AI summary

A microneedle array has a plurality of microneedles, said microneedles being supported by a substrate. In order to improve the properties of the microneedle array, the substrate is in the form of a grid structure or comprises a grid structure.